Prefabricated concrete wall and roof form structure



F. F. SOUKUP May 24, 1966 PREFABRICATED CONCRETE WALL AND ROOF FORMSTRUCTURE 4 Sheets-Sheet 1 Filed Aug. 17, 1960 INVENTOR FABIAN F. SOUKUPIla-El ATTORNEY F. F. SOUKUP May 24, 1966 PREFABRICATED CONCRETE WALLAND ROOF FORM STRUCTURE 4 Sheets-Sheet 2 Filed Aug. 17, 1960 INVENTOR.

FABIAN F. SOUKUP ATTORNEY May 24, 1966 F. F. SOUKUP 3,252,682

PREFABRICATED CONCRETE WALL AND ROOF FORM STRUCTURE Filed Aug. 17, 19604 Sheets-Sheet 5 11" i-.j "11 l 400 I I E En INVENTOR.

FABIAN F. SOUKUP BY M ATTORNEY May 24, 1966 F. F. SOUKUP 3,252,682

PREFABRIGATED CONCRETE WALL AND ROOF FORM STRUCTURE Filed Aug. 17, 19604 Sheets-Sheet L INVENTOR.

FABIAN F. SOUKUP ATTORNEY United States Patent 3,252,682 PREFABRICATEDCONCRETE WALL AND ROQF FORM STRUCTURE Fabian F. Soukup, Box 322,Healdsburg, Calif. Filed Aug. 17, 1960, Ser. No. 50,222 7 Claims. (Cl.249158) This invention relates to prefabricated concrete wall and roofforms. More particularly the present invention relates to structures ofthis character wherein the concrete units are reinforced by prestressedsteel members.

Prefabricated wall slabs or sections have been used widely for a numberof years in building construction. By prefabricated wall slab or sectionis meant a wall slab or section made of concrete in a horizontal formand then tilted up, after removal of the form, to vertical position.

There is an advantage in applying such technique to wall and roof unitsbut extension of the technique to include a roof section integral with awall section is difficult. A three dimensional structure of thischaracter, that is, a structure which is not flat and which has a thirddimension of large magnitude, is not easy to construct as one integralunit, and the structure is difficult to manipulate.

It is another particular object of the invention to provide a facile,dependable means of prefabricating integral wall and roof units ofconcrete.

The above and other objects of the invention will be apparent from theensuing description and the appended claims.

Inasmuch as the terms prestressing, pretensioning and post-tensioningare used herein, it is appropriate to define them.

Prestressing, as used herein, refers to the practice of applying tensionto reinforcement members in concrete before a load is applied to theconcrete. Prestressing can be carried out by pre-tensioning or bypost-tensioning. In the former case (pre-tensioning) reinforcementcables or the like embedded in concrete are pulled or tensioned beforethe concrete has set and hardened. In the latter case (post-tensioning)the reinforcement cables or the like are pulled or tensioned after theconcrete has set and hardened sufficiently to take compression, and itis accomplished by laying the cables in tubes which are embedded in theconcrete, pulling the cables after the concrete has set and hardened,then filling the tubes with a concrete or grout mix and allowing it toharden. These are known techniques with which those skilled in the artare well acquainted.

Certain forms of the invention are illustrated by way of example in theaccompanying drawings, in which:

FIGURE 1 is a perspective View of a form used in ac cordance with theinvention to construct a concrete wall and roof unit.

FIGURE 2 is a transverse section taken through the form of FIGURE 1shown filled with concrete.

FIGURE 3 is a perspective view of a filler strip employed with the formof FIGURE 1 to control the depth of the column and of the beam or rafterportions of the end product.

FIGURE 4 is a view in vertical midsection of the form of FIGURE 1 withconcrete cast in place and with pretensioned reinforcement members alsoin place.

FIGURE 5 is a view similar to FIGURE 4 but wherein the reinforcementmembers are post-tensioned.

FIGURE 6 is a view in side elevation of a wall and roof unit constructedin accordance with the invention.

FIGURE 7 is a section taken along the line 77 of FIGURE 6.

FIGURE 8 is a view in end elevation of a building structure showing twowall and roof units (such as that shown in FIGURES 6 and 7) in erect,abutting relation.

3,252,682 Patented May 24, 1966 FIGURE 9 is a perspective view of amodified type of form wherein the column and rafter elements of the walland roof sections are intended to be on the exterior surface.

FIGURE 10 is a view in end elevation of a modified form of roof and wallunit in accordance with the invention.

Referring now to the drawings and more particularly to FIGURE 1, a formis shown at 10 comprising a framework made up of base members 11,vertical members 13, and cross members 14. The framework 11 may be ofwood, steel, aluminum or any other desirable type of construction. Itserves to support a form or mold surface 16 and side strips 17. It willbe seen that the form surface 16 is in two sections, 16a and 161), whichadjoin one another at a peak 18 and which slope outwardly and downwardlytherefrom to form an inverted V. Each of the sections 16a and 16b isformed with a channel 19 which tapers in depth from the peak 18 to thebottom edge of the respective surface, so that the channel is deepest atthe junction of the surface 16a or 16b and diminishes progressively indepth therefrom.

In effect a double form 10a and 10b is thereby provided. The form 10a,as explained hereinafter, is employed to produce a wall section and theform 10b is employed to produce a roof section. Each form section 10a or101) is channel-shaped in cross section as shown in FIGURE 2 and ittapers in cross section so that it is deeper near the center line. Asthere shown a bulkhead 25 is provided. The bulkhead 25 conforms to thecross sectional shape of the mold, it is movable to adjust the height ofthe wall section and the span of the roof section, and it is removable.It is held in place during use by any suitable means (not shown) such aswedges or nails. There is, of course, one bulkhead for each mold section10a and 10b, and preferably an assortment of bulkheads is provided toconform to the carrying depth of the channels 19.

Referring to FIGURE 3 a filler strip is shown which is designated by thereference numeral 30 and which is tapered as shown. A number of suchfiller strips are provided for each mold section 10a and 10b and each ofthem fits into its respective channel 19. Its purpose is to adjust thedepth of the respective channel 19. The filler strips 31 are ofdifferent thickness so that the channels 159 can be adjusted for aparticular design. For example, if a shorter length of wall or a roof ofshorter span is to be made, the channels 19 will be made shallower byselecting thicker filler strips.

Referring now to FIGURE 4, the form 10 is there shown in verticalmidsection. The bulkheads 25 are shown in place. Also shown are steelcables 31 extending over the peak 18 and supported by members such asshown at 32 which serve to space the cables from the bottom of the form.(Conventional steel reinforcement rods are shown at 31a which are notprestressed and which serve to provide strength for handling andcompress-ion purposes.) The ends of the cables 31 are shown secured toanchor members 33. Each cable will be pulled by a suitable means (notshown) such as jacks to apply a suitable tension and thereby prestressthe cable. All inner surfaces of the form in contact with the concretemay be coated with a suitable release agent. Concrete is then pouredinto the for-m starting at the bottom of each section 10a and ltlbadjacent the respective bulkhead 2S and progressing upwardly to the peak18. The concrete mix, after having been poured, is screeded and leveledoff flush with the side rails 17 and the bulkheads 25. Two or more hooks35 will be embedded :in the concrete before it hardens, such hooks beingemployed to hoist and manipulate the precast concrete unit when it isready for removal from the form. The concrete is allowed to set andharden sufiiciently to withstand the strain of lifting and removal fromthe form 10. Suitable lift means (not shown) such as a crane is used tohoist the concrete unit, employing the hook or hooks 35 to assist inthis operation.

Referring now to FIGURES 6 and 7, the resulting precast, prestressed,concrete roof and wall unit is there shown at 40. It is T-shaped incross section as shown in FIGURE 7, comprising a body portion 41 and acolumn element 42a (or a rafter element 421)). The body portion 41 asshown in FIGURE 6 comprises a wall section 41a and a roof section 41b.Shown in the wall section 41a are a door opening 43 and a window opening44. Shown in the roof section 41b are roof openings 45 and 46, forexample, for vents, pipes, chimneys, etc. Openings such as those shownat 43, 44, 45 and 46 are very easily provided, whenever they are needed,by blocking off parts of the form 10 and then removing the blockingmembers after the concrete has hardened, thereby leaving openings suchas those shown at 43, 44, 45 and 46 in FIGURE 5.

Referring to FIGURE 8, two roof and wall units 40 are there shown inerect position, each comprising a wall section 40:: and a roof section40b. These are shown with the wall sections 40a upright and the roofsections 4011 abutting to form a peak.

It will be understood that the roof sections 40b can be tied together atthe peaks by any suitable means wellknown in the art and that the wallsections 40a can be seated upon and tied to a foundation by any suitablemeans (not shown). By repeating this operation a building of any desiredlength can be erected very rapidly.

The structural shape shown at 40 in FIGURES 6, 7 and 8 is advantageous.It provides both a wall section and a roof section. By using prestressedand pre-tensioned reinforcement members and by using the tapered columnand rafter elements shown, a very strong structure is provided. Theforms shown are very advantageous because they facilitate casting thestructures and they also facilitate storage and transport. For example,a large number of forms can be used and the concrete structures left onthe forms and/or transported while still on the forms. Alternativelyonly one or a few forms can be employed.

Among other advantages the following may be mentioned: The units 40 lendthemselves to transportation by rail and by truck or highways. Forexample, a roof and wall unit 40 for a building having a fifty foot spancan be laid on the bed of a truck or trailer and fall within thetolerance limits on height which are specified in many of the States.The system is flexible because it offers a choice of making the units ata central plant and transporting the finished unit to the constructionsite, or making the units at the site. Also, the units are easilylifted, e.g., by a single crane.

The technique described with reference to FIGURE 4 comprisespre-tensioning the cables 31. FIGURE illustrates how post-tensioning canbe carried out in accordance with the invention. The form 10 is the sameas that shown in FIGURE 4, and similar parts are similarly numbered.However, tubes 50 are supported in the form by any suitable means andreinforcement cables 31 are passed through these tubes. (Conventional,non-prestressed steel rods are provided at 31a as in FIGURE 4.) Concreteis poured, screeded and levelled as described above in connection withFIGURE 4, and it is allowed to set and harden enough to resistcompression. Then the steel cables 31 are tensioned. Thispost-tensioning can be accomplished by fastening keeper members (notshown) to one end of each cable, and applying a jack to the other end ofeach cable, the jack reacting against the concrete structure. Then eachtube 50 is filled with a grout or concrete mix, which is allowed to setand harden. Then the protruding ends of the cables are cut off. Theorder of post-tensioning and filling the tubes 50 with grout or concretemay be reversed. The tubes 50 can be filled with grout or concrete byforcing the wet mix into one end of each tube 50 until it comes out theother end. Alternatively, a filler tube 51 may connect to each tube 4 50at its peak and the met mix filled through this tube, which will be cutoff after the tubes 50 have been filled.

This technique of post-tension ing is advantageous for on-site jobs,where units 40 are made at the construction site and where the extraequipment used in the pre-tensioning technique is not available. Thus,all that is needed is a means of anchoring the form 10 and cast unit 40,and a means such as a winch and pulleys, or a jack to post-tension thecables 31.

Referring now to FIGURE 9, an inverted form is there shown which isgenerally designated by the reference number 55. It comprises twosections 10a and 10b as in the case of the form 10 shown in FIGURE 1.However, the sections 10a and 10b form a valley with its low point at18. The numeral 56 indicates generally a framework or support for thisform which may be a solid block or a wooden or steel framework such asthat shown in FIGURE 1, suitably modified.

Bulkheads, filler strips and blocking members will be employed as in thecase of form 10 in FIGURE 1. Also, cables will be located within theform as described above in connection with FIGURE 4 or FIGURE 5 and willbe preor post-tensioned cables. Concrete will be poured commencing atthe low point 18 and moving upwardly along each section 10a and 10b. Theconcrete will be screeded, levelled, allowed to set and harden and thenremoved from the mold. The resulting precast, prestressed concrete roofand wall unit Will be identical with that shown in FIGURES 6, 7 and 8except that the column and rafter elements will be on the outside of theunit rather than on the inside.

Referring now to FIGURE 10, an end elevational view of a prestressed,precast concrete unit 60 is there shown having a body portion 61 and aportion 62 constituting the column element of a wall section or therafter element of a roof section. As will be seen, the portion 62 isformed with a longitudinal passage 63. This structure will be made inthe same way as the structure 40 shown in FIGURES 6, 7 and 8 except thatthe channel 19 of the form 10 will have a suitable blocking memberlocated within it to 'block out a portion of the channel, such blockingmember being removable when the concrete has set and hardened.Alternatively if the blocking member is hollow, it may remain in thefinished concrete structure. The passageway 63 has the advantage that itlightens the Weight of the finished product. Also, these passagewaysserve as ducts to carry piping, for flow of a heating or cooling fluidand for other purposes.

It will, therefore, be apparent that a novel and very useful structuralshape has been provided consisting of an integral, precast andpreferably prestressed concrete wall and roof section, and that a verynovel and advantageous means of prefabricating such an article has beenprovided. The invention has been described in relation to wall and roofsections wherein the roof forms an obtuse angle with the wall. However,the invention can be applied to sections with a flat roof to the wall)and it can also be applied to inverted V-shaped structures wherein thesloping wall sections are formed which come together at an acute angle.The technique has desirable features of adjustability. For example, asingle form such as shown at 10 in FIGURE 1 can be adjusted for thickerand thinner slabs by adjusting the side walls 17, for shorter or longerslabs by adjusting the bulkheads 25 and for deeper or shallower ribs byselection of filler strips 30.

I claim:

1. A form for producing a monolithic precast concrete structurecomprising a pair of form sections,

each of said sections including a bottom surface sufficiently wide toform a building wall or roof section, upright walls secured along thesides of said surface to confine fluid concrete to the desired thicknessof side wall or roof section, and a unitary channel 5 6 member dependingfrom and opening into said bOt- 7. The form of claim 1 wherein saidsections diverge tom surface for formation of an integral reinforcingupwardly from said apex. column or beam, said sections being joined atadjacent ends with the References Cited y the Examiner bottom surfacesand the channels thereof disposed 5 UNITED STATES PATENTS at relativelyfixed angles to each other and to the horizontal for formation of acontinuous wall and roof section with integral column and beams.

2. The form defined in claim 1 wherein the channel depending from thebottom surfaces of 10 each section is progressively deeper toward saidadjacent ends.

3. In combination with the form defined in claim 1 spacer membersinsertable in said sections and adapted 2,031,899 2/1936 Mattes 25-12,280,832 4/1942 Ketcham.

2,294,528 9/ 1942 Wells.

2,393,055 1/1946 Negrin.

2,455,153 11/1948 Abeles.

2,750,646 6/1956 Reidenbach 251 2,786,349 3/1957 Golf.

2,897,688 8/1959 Graham.

3 041 702 7/ 1962 Schwab 2S154 to support metal reinforcement membersalong the 15 lengths of said Sections 3,055,146 9/1962 Lobato 25118 4.The form defined in claim 1 including FOREIGN PATENTS members insertablein said sections to blank out wall 652 483 10/1928 France or rootopenings. 2 1 47 5. The open form defined by claim 1 including 20 6 519952 2: 2: 2

21 bulkhead for each section which is removable from and insertable inits respective section at a selected SPENCER ()VERHOLSER, PrimaryExaminer,

dlstance from sa1d oint ad acent ends to conform JACOB L NACKENOFFMORRIS LEIBMAN ALEX ilegigaglgistgrltiis cross section of sa1d sectionat sa1d ANDER H. BRODMERKEL, Examiners.

2o 6. The form of claim 1 wherein said sections diverge R. B. MOFFITI,J. SHAPIRO, Assistant Examiners. downwardly from said apex.

1. A FORM FOR PRODUCING A MONOLITHIC PRECAST CONCRETE STRUCTURECOMPRISING A PAIR OF FORM SECTIONS, EACH OF SAID SECTIONS INCLUDING ABOTTOM SURFACE SUFFICIENTLY WIDE TO FORM A BUILDING WALL OR ROOFSECTION, UPRIGHT WALLS SECURED ALONG THE SIDES OF SAID SURFACE TOCONFINE FLUID CONCRETE TO THE DESIRED THICKNESS OF SIDE WALL OR ROOFSECTION, AND A UNITARY CHANNEL MEMBER DEPENDING FROM AND OPENING INTOSAID BOTTOM SURFACE FOR FORMATION OF AN INTEGRAL REINFORCING COLUMN ORBEAM, SAID SECTIONS BEING JOINED AT ADJACENT ENDS WITH THE BOTTOMSURFACES AND THE CHANNELS THEREOF DISPOSED